US8186566B2 - Method for cohesively bonding metal to a non-metallic substrate - Google Patents
Method for cohesively bonding metal to a non-metallic substrate Download PDFInfo
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- US8186566B2 US8186566B2 US12/045,347 US4534708A US8186566B2 US 8186566 B2 US8186566 B2 US 8186566B2 US 4534708 A US4534708 A US 4534708A US 8186566 B2 US8186566 B2 US 8186566B2
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
- B29C65/081—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations having a component of vibration not perpendicular to the welding surface
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
- B29C65/64—Joining a non-plastics element to a plastics element, e.g. by force
- B29C65/645—Joining a non-plastics element to a plastics element, e.g. by force using friction or ultrasonic vibrations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
- B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protusions or cavities belonging to at least one of the parts to be joined
- B29C66/30321—Particular design of joint configurations the joint involving an anchoring effect making use of protusions or cavities belonging to at least one of the parts to be joined making use of protusions belonging to at least one of the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
- B29C66/3034—Particular design of joint configurations the joint involving an anchoring effect making use of additional elements, e.g. meshes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/45—Joining of substantially the whole surface of the articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
- B29C66/72143—Fibres of discontinuous lengths
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/02—Iron or ferrous alloys
- B23K2103/04—Steel or steel alloys
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/02—Iron or ferrous alloys
- B23K2103/04—Steel or steel alloys
- B23K2103/05—Stainless steel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/14—Titanium or alloys thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
- B29C66/7316—Surface properties
- B29C66/73161—Roughness or rugosity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
- B29K2105/122—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles microfibres or nanofibers
- B29K2105/124—Nanofibers
Definitions
- the present invention relates generally to a method for cohesively bonding metal to a non-metallic substrate and more particularly, to the use of metallic micro and nano size filaments, embedded into the non-metallic material, to create cohesive bonds with the metallic material.
- Non-metallic materials and in particular composite materials such as graphite-fibers or fiberglass fibers with epoxy matrices, are notoriously difficult to attach to metallic materials.
- the most used methods to create such assemblies are adhesive bonding or the use of fastening devices. Both of these methods have disadvantages related to disbanding due to water infiltration and corrosion or due to the fracture of the superficial surfaces where the fastening devices are connected to the composite material.
- Welding in general, is making use of high temperatures to melt the two metals in contact with each other or to melt a filler material, creating a pool of common, molten alloy that when solidifies, would strongly connect the two together.
- the diffusion bonding process is known to create a strong bond between two metals without melting them by using only pressure and lower temperatures, and without the introduction on any extrinsic material.
- bonding a metal surface to a non-metallic substrate generally cannot be accomplished by any of the methods outlined above and often requires the addition of an extrinsic material, such as an adhesive.
- an extrinsic material such as an adhesive
- a method for cohesive bonding a metal body to a substrate comprising the steps of contacting the metal body to a surface of the substrate, the substrate comprising a plurality of microfilaments or nanofilaments dispersed into or below the surface of the substrate and the metal body surface comprising microscopic asperities which contact the plurality of microfilaments or nanofilaments, applying normally-oriented pressure on the metal body and laterally-oriented high frequency and low amplitude vibrations to the substrate and forming a cohesive bond between the metal body and the substrate.
- a method for cohesive bonding a metal body to a substrate comprising the steps of coupling a plurality of capacitors to the metal body and the substrate, contacting the metal body to the substrate, the substrate comprising a plurality of microfilaments or nanofilaments, wherein the microfilaments or nanofilaments provide microscopic asperities on at least the substrate surface which contacts the metal body, discharging energy from the plurality of capacitors to raise the temperature of the surfaces of the metal body and the substrate which contact one another, applying pressure on the metal body or substrate and forming a cohesive bond between the metal body and the substrate.
- a method for cohesive bonding a metal body to a substrate comprising the steps of contacting the metal body to the substrate, the substrate comprising a plurality of microfilaments or nanofilaments, wherein the microfilaments or nanofilaments provide microscopic asperities on at least the substrate surface which contacts the metal body, positioning a sonotrode to contact the metal body, applying normally-oriented pressure on the metal body or substrate, vibrating the metal body or substrate and forming a cohesive bond between the metal body and the substrate.
- FIG. 1 is a schematic of composite material comprising a matrix and fibers having a plurality of microfilaments and/or nanofilaments embedded in the matrix;
- FIG. 2 is a schematic of the composite material of FIG. 1 with a metal body to be bonded to the matrix;
- FIG. 3 is a schematic of the metal body of FIG. 2 being compressed to the matrix
- FIG. 4 is a schematic of a metal body being bonded to a non-metallic substrate via capacitor-discharge bonding
- FIG. 5 is a schematic of a metal body being bonded to a non-metallic substrate via localized friction bonding
- FIG. 6 is a schematic of a metal body being bonded to a non-metallic substrate via ultrasonic welding.
- FIG. 7 is a schematic showing an enlarged view of the bond formed as the result of the method of the present invention between a metal surface and a substrate comprising microfilaments and/or nanofilaments.
- the present invention provides methods for cohesively bonding the surface of a metal body to a non-metallic substrate which may comprise contacting a metal surface of the metal body with a surface of the substrate.
- the substrate may comprise a plurality of microfilaments and/or nanofilaments which may provide microscopic asperities on the surface of the substrate in contact with the metal surface.
- the method may further use a variety of known joining process such as: friction welding, capacitor-discharge welding, ultrasonic welding and diffusion bonding to connect the filaments with the metallic body.
- These methods may comprise simultaneously applying normally-oriented pressure to the metal surface and laterally-oriented high frequency and low amplitude vibrations to the substrate and forming a cohesive bond between the metal surface and the substrate.
- the applied loads are typically below those loads which would cause macro-deformation of the components' materials.
- This process known as localized friction welding, creates localized increases of contact temperature that do not exceed 0.5-0.8 times the melting point temperature of such materials and the temperature of the materials can remain in this range for 0.004 seconds to over 3600 seconds depending upon the type of materials being bonded, the joint properties of these materials, and the heating method being used.
- joining processes may comprise radiant heating, induction heating and direct or indirect resistance heating.
- the diffusion bonding process may be further assisted by additionally exposing the components' materials to higher temperatures, inert gases and/or a vacuum.
- the cohesive bond may be formed by diffusion of the microfilament and/or nanofilament material into the metal layer, thus forming a stronger bond than one without the presence of the microfilaments and/or nanofilaments.
- the substrate 14 comprises a matrix that may include fibers 18 and a plurality of microfilaments and/or nanofilaments 16 randomly oriented and embedded within the matrix.
- the microfilaments and/or nanofilaments 16 are metallic, but alternatively they may comprise ceramic, plastic, or any other material known to the skilled artisan. Some or all of the plurality of microfilaments and/or nanofilaments 16 may extend out of a surface 15 of the substrate 14 , whereas others may be embedded in the substrate without extending out of the substrate.
- substrate 14 of FIG. 1 may be any material desired to form a bond to a metal surface 12 and which may have microfilaments and/or nanofilaments 16 dispersed therein.
- the substrate 14 comprises non-metallic material.
- the substrate 14 may comprise a composite material such as, but not limited to, a metal matrix composite, a ceramic composite or a polymer composite.
- the polymer composite may comprise unidirectional or multidirectional oriented fibers of graphite, fiberglass, aramid or a combination thereof.
- Substrate 14 may comprise any size or form desired. It may be preformed into a desired shape or part. Alternatively, it may be shaped or formed after bonding to the metal surface.
- the substrate 14 may comprise a plurality of microfilaments and/or nanofilaments 16 .
- the plurality of microfilaments and/or nanofilaments 16 may be dispersed on and below a surface 15 (see FIG. 1 ) of the substrate 14 .
- the plurality of microfilaments and/or nanofilaments 16 are introduced individually into the substrate 14 and may create an intricate network in the substrate 14 .
- the plurality of microfilaments and/or nanofilaments 16 may be introduced into the substrate 14 being physically connected to one another, forming a structure such as, but not limited to, a micrometric or nanometric sized foam. It will be appreciated that a network of microfilaments and/or nanofilaments 16 may provide firstly, a strong adhesion bond within the substrate 14 and subsequently provide the opportunity for bonding between metal surface 12 and substrate 14 .
- a metal-bonded substrate is shown in FIG. 2 .
- a metal body 12 may be cohesively bonded to the substrate 14 via one of several bonding methods, three of which will be described below in further detail.
- the substrate 14 in FIG. 2 may comprise a plurality of randomly-oriented microfilaments and/or nanofilaments 16 and a plurality of aligned fibers 18 dispersed throughout substrate 14 and which are usually introduced as a specially fabricated cloth.
- the microfilaments and/or nanofilaments 16 may form microscopic asperities on the surface 15 of the substrate 14 and may change the material characteristics of the substrate 14 at or near the surface 15 .
- the plurality of microfilaments and/or nanofilaments 16 may be dispersed in the substrate 14 during the manufacture of the substrate 14 . Alternately, the microfilaments and/or nanofilaments 16 may be dispersed in the substrate 14 afterwards by other methods known in the art.
- the plurality of microfilaments and/or nanofilaments 16 may be distributed throughout the substrate 14 to provide the optimal cohesive bond between the substrate 14 and the surface of the metal body 12 .
- the plurality of microfilaments and/or nanofilaments 16 may be evenly distributed throughout the substrate 14 or they may be concentrated at the surface 15 of the substrate 14 where the surface of the metal body 12 will be bonded, gradually decreasing in the substrate 14 away from the surface 15 .
- the microfilaments and/or nanofilaments 16 may comprise a material capable of bonding with the metal body 12 .
- the microfilaments and/or nanofilaments 16 may comprise a metal such as, but not limited to, stainless steel or a titanium alloy.
- the microfilaments and/or nanofilaments 16 may comprise a material capable of sustaining the bond or joint between the substrate 14 and the metal body 12 and may also have desired corrosion resistance as well as little or no adherent oxide layer.
- those filaments 16 may have a diameter of less than 100 nm up to 1000 nm in cross-sectional dimension.
- nanofilaments 16 produced using other, advanced technologies may be less than about 100 nm in cross-sectional dimension. It will be appreciated that the cross-sectional dimension of the nanofilaments 16 may be small enough to provide an optimal number of interactions with the metal body 12 but still retain integrity and strength. Based on the present technology the nanofilaments 16 may have a length less than about 400 ⁇ m.
- the nanofilaments 16 may be made by processes known in the art such as, but not limited to, the process described in U.S. Pat. No. 6,444,256, which is herein incorporated by reference
- the surface of the metal body 12 may be the surface of a metal strip, a metal sheet, a metal plate or a metal block. It is contemplated that any metal surface found on any part or material may be bonded to the substrate 14 using the process of the present application.
- the metal surface 12 may comprise any metal having the desired properties for the application in which the bonded metal and composite complex 10 are to be used.
- the metal body surface 12 may comprise stainless steel or titanium.
- a method for cohesive bonding a metal surface 12 to a substrate 14 is provided.
- pressure may be applied in a direction 11 against the metal body 12 such that the metal body 12 is compressed against the substrate 14 .
- the pressure can be applied uniaxially or isostatically.
- Uniaxial pressure generally requires lower pressure in the range of 3-10 MPa to avoid macro-deformation of the bonded materials. Additionally, this process typically requires good surface finish on the mating surfaces as the contribution to bonding provided by plastic yielding is restricted. In general, surface finishes with roughness values better than 0.4 ⁇ m RA and which are free from contaminants are advantageous for bonding purposes.
- isostatic pressure much higher pressures such as 100-200 MPa may be possible and therefore surface finish is not as critical.
- FIG. 4 An exemplary method for cohesive bonding is shown in FIG. 4 known as capacitor-discharge welding.
- a substrate 14 is provided which includes fibers 18 and a plurality of microfilaments and/or nanofilaments 16 embedded in the substrate 14 .
- a metal body 12 is brought into contact with a surface of the substrate 14 such that a portion of the plurality of microfilaments and/or nanofilaments 16 found on the surface 15 of substrate 14 may contact the metal body 12 .
- Capacitors (not shown) are provided to be coupled to at least one of the metal body 12 and substrate 14 through contact elements 25 .
- Contact elements 25 may be placed onto at least one surface of the metal body 12 and/or substrate 14 .
- Energy stored in the capacitors at specific voltages may be released or discharged through contact elements 25 to 14 and 12 .
- an instantaneous arc may be created which melts the adjoining surfaces of the metal body 12 and microfilaments and/or nanofilaments 16 .
- pressure may be applied to both materials such that the materials compress against one another and a cohesive bond is formed between the metal body 12 and microfilaments and/or nanofilaments 16 , as the molten metal solidifies.
- the capacitor-discharge welding process is an extremely efficient method for welding a wide variety of metals including mild steel, stainless steel, aluminium, brass, copper, titanium, and other similar metals.
- a powerful bank of capacitors may be provided with each capacitor storing energy at a specific voltage.
- the capacitors may range between 450-3000 volts. The voltage may depend on the size and material of the component being formed.
- Large capacitor-discharge welding machines may output 400 KA of current and 50 kJ of energy. When energy is discharged, a cohesive bond may be formed in approximately 0.004 seconds or more.
- the capacitor-discharge welding process is advantageous for many reasons.
- the short welding time localizes the heat and creates welds adjacent to heat sensitive portions of the material.
- the capacitor-discharge welding process provides excellent bonding with a variety of similar and dissimilar materials without requiring any water cooling, significant power requirements, nor substantial operating costs for high production rates. This process may be performed in most environments as it does not require large amounts of space and produces very little, if any, fumes or smoke.
- the method may comprise the step of contacting a metal body 12 with a surface 15 of a substrate 14 .
- the substrate 14 may comprise a plurality of microfilaments and/or nanofilaments 16 dispersed into and below the surface 15 of the substrate 14 .
- the surface of the metal body 12 may have microscopic asperities (not shown) as it will be appreciated most metal surfaces are not absolutely smooth.
- the microscopic asperities 17 of the surface of the metal body 12 may come into contact with the microfilaments and/or nanofilaments 16 of the substrate 14 .
- the microfilaments and/or nanofilaments 16 provide microscopic asperities that aid in the bonding process and may contact the microscopic asperities 17 of the metal body 12 .
- the method may also comprise the step of simultaneously applying normally-oriented pressure 20 on the metal body 12 and laterally-oriented high frequency and low amplitude vibration 22 to the substrate 14 as shown in FIG. 5 .
- the application of the combined pressure and vibration may produce high temperatures localized between the adjoining surface of the metal body 12 and the microfilaments and/or nanofilaments 16 and may further facilitate metal transfer between the metal body 12 and the material of the microfilaments and/or nanofilaments 16 that is exposed at the surface 15 of the substrate 14 . This metal transfer may result in a
- Friction bonding generally is a solid phase pressure welding process where little to no actual melting of the metal body occurs. By rubbing the adjoining surfaces of the metal body and the substrate together, sufficient heat is produced for creating local plastic zones. Accordingly, two atomically clean metal surfaces may be brought together under pressure and an inter-metallic bond is formed. The corresponding heat may be confined to the interface of the two materials. The heat input may be low and the amount of work applied to the bonded area results in grain refinement.
- friction bonding One advantageous characteristic associated with friction bonding is the ability to weld alloys and combinations of alloys which were previously regarded as “un-weldable.” With localized friction bonding processes, it is now possible to produce dissimilar metal joints, join steel, copper, and aluminium to themselves and/or to each other, and to successfully weld alloys.
- the method may comprise the step of contacting a metal body 12 with a surface 15 of a substrate 14 .
- the substrate 14 may comprise a plurality of microfilaments and/or nanofilaments 16 dispersed into and below the surface 15 of the substrate 14 .
- the surface of the metal body 12 may have microscopic asperities as it will be appreciated most metal surfaces are not absolutely smooth.
- a sonotrode 26 may be positioned to be in contact with a surface of the metal body 12 .
- an anvil 27 may be positioned against a surface of the substrate 14 and it holds the materials to be welded statically together.
- a welding tool may attach or couple to the material to be bonded and the tool moves in a longitudinal direction.
- the metal body 12 and substrate 14 may be pressed together and a generator (not shown) may produce electrical oscillations of ultrasonic frequency.
- a transducer (not shown) may convert the electrical oscillations into mechanical vibration which in turn is transmitted to the sonotrode 26 .
- the sonotrode transmits the ultrasonic vibrations 28 to the metal body 12 and substrate 14 .
- the sonotrode 26 needs to be mounted tightly to the metal body 12 to avoid friction and other losses. The simultaneous action of static and dynamic forces causes the metal body 12 and substrate 14 to fuse together without requiring the addition of an extrinsic material.
- Vibrations may reach frequencies of about 20-70 kHz.
- a complex process is triggered involving static forces, oscillating shearing forces, and a moderate temperature increase in the welding area. The magnitude of these factors depends on the thickness of the work pieces (viz., the metal body 12 and substrate 14 ), their surface structure, and their mechanical properties. Typical frequencies may reach 20-40 kHz, which is above the frequency that is audible to a human ear and also permits the best possible use of energy.
- ultrasonic welding is used for forming small components that require less energy such as watches, cassettes, plastic products, toys, medical tools, and packaging.
- a resulting component 24 is formed from cohesive bonding between a metal body 12 and a substrate 14 .
- the metal body 12 may include microscopic asperities and the substrate may include a plurality of microfilaments and/or nanofilaments 16 .
- Other components may be formed via any of the above-described methods and the type of component being made should not be limiting.
Abstract
Description
Claims (11)
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US12/045,347 US8186566B2 (en) | 2007-03-10 | 2008-03-10 | Method for cohesively bonding metal to a non-metallic substrate |
US13/462,926 US8397976B2 (en) | 2007-03-10 | 2012-05-03 | Method for cohesively bonding metal to a non-metallic substrate using capacitors |
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US89421307P | 2007-03-10 | 2007-03-10 | |
US12/045,347 US8186566B2 (en) | 2007-03-10 | 2008-03-10 | Method for cohesively bonding metal to a non-metallic substrate |
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US8186566B2 true US8186566B2 (en) | 2012-05-29 |
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US13/462,926 Expired - Fee Related US8397976B2 (en) | 2007-03-10 | 2012-05-03 | Method for cohesively bonding metal to a non-metallic substrate using capacitors |
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US9434134B2 (en) | 2008-08-18 | 2016-09-06 | Productive Research Llc | Formable light weight composites |
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US11331880B2 (en) | 2010-02-15 | 2022-05-17 | Productive Research Llc | Delamination resistant, weldable and formable light weight composites |
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Also Published As
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US20120273125A1 (en) | 2012-11-01 |
US8397976B2 (en) | 2013-03-19 |
US20080217379A1 (en) | 2008-09-11 |
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